7. maintenance depot and workshop - mumbai railway … chapter 7... · 7. maintenance depot and...

TECHNO-ECONOMIC SURVEY AND PREPARATION OF DPR FOR PANVEL-DIVA-VASAI-VIRAR CORRIDOR

Draft Feasibility Report APRIL, 2013 7-1

77.. MMAAIINNTTEENNAANNCCEE DDEEPPOOTT AANNDD

WWOORRKKSSHHOOPP

7.1 INTRODUCTION

The Panvel-Virar Suburban corridor would require a dedicated Depot cum workshop

facility for the maintenance of the rakes. The total coach holding would increase to

about 576i.e 48 Rakes of 12 car in the horizon year 2041 to meet the traffic demand.

All the rakes will be serviced at main Depot cum workshop for the scheduled

inspections, major schedules viz Periodical overhaul (POH) and major unscheduled

repairs. The main depot will also house Operation Control Centre (OCC),

Administrative Building, maintenance facilities for Civil – track, buildings, water

supply; Electrical – traction, E&M; Signalling & Telecomm.; etc. apart from necessary

facilities viz stabling lines, scheduled inspection lines, workshop for overhaul,

unscheduled maintenance including major repairs, wheel profiling, heavy

interior/under frame/roof cleaning etc. for the rolling stock operational on the

corridor.

For starting the morning services, some rakes will have to be kept at terminal

stations and stabling facilities for the remaining rakes will have to be provided at the

depots.

All the systems at the depot would be designed to cater for 12 Car composition

trains in order to serve the ultimate passenger traffic on Panvel-Virar suburban

corridor.

This chapter covers following aspects of depot -

• Conceptual design of Stabling lines, Inspection Shed and Workshop to provide

maintenance facilities and stabling facilities for the Rolling Stock.

• Operational and functional safety requirements.

• Ancillary buildings for other maintenance facilities.

• Electrical & Mechanical Services, power supply system etc.

• Location for Depot cum Workshop

This section provides conceptual design of the depot and will only work as a guide

for the detailed design later.

7.2 MAINTENANACE PHILOSOPHY

The main outlines of the maintenance philosophy followed are:



� Monitoring of the performance of equipment by condition monitoring of key

parameters. The concept is to progressively evolve the need based

maintenance regime, which can be suitably configured in the form of minor &

major schedules.

� Unit replacement and to get essential repairs done by the OEMs, will be

preferred. Since the cost is a constraint, certain activities of the workshop can

be outsourced.

� Labour intensive procedures be kept to the minimum & emphasis laid on

more automation with state of the art machinery to ensure quality with

reliability.

� Multi skilling of the Maintenance staff to ensure quality and productivity in

their performance.

� Energy conservation shall be given due attention

7.3 PLANNING OF THE MAINTENANCE FACILITIES SETUP

The projected Rolling Stock requirements for the corridor are as follows:

Table 7.1

Year 2021 2026 2031 2041 Designed

Headway (minutes) 15 12 8 5 3

No of Cars/Train 12 12 12 12 12

Rakes Required 19 21 33 48 78

Coaches Required 228 252 396 576 936

The operation plan envisages 12-car rakes operation at 15 minutes headway in the

inception year 2021, requiring total 228 coaches (19 Rakes of 12 car each). The

services increase to 5 minutes headway in the horizon year 2041, requiring total 576

coaches (48 Rakes of 12 car each) as the traffic demand grows.

7.4 ROLLING STOCK MAINTENANCE NEEDS

The servicing requirement is to be determined from the Rolling Stock manufacturer.

Depending upon manufacturer's requirements, servicing facilities may be provided

to include the ability to carry out the inspection, maintenance, overhaul and repair of

the rolling stock fleet, including the following components:

� Body;

� Bogies;

� Wheels;

� Traction motors;



� Electrical components;

� Electronics; PA/ PIS

� Mechanical components;

� Batteries;

� Rolling stock air conditioning;

� Brake modules;

� Vehicle doors, windows and internal fittings.

The modern, fully equipped facilities are proposed to be provided to meet these

requirements efficiently and in full. In meeting these requirements, it is envisaged

that the average daily distance travelled by each rolling stock unit is approximately

650 km.

The following maintenance schedule recommended by RDSO in Para (k) of SMI no.

RDSO/PE/SMI/EMU/0037-2007(rev.0) dated April-2007, has been followed for

conceptual design -

Table 7.2: Periodicity of Maintenance Schedules for Rakes

Schedule Periodicity

As per SMI With 10 days frequency

Trip Schedule (TI) 10 days 10 days

IA Inspection 45 days 40-50 days

IC Inspection 180 days 180-190 days

POH 18 months 18 months (540 days)

7.5 WASHING NEEDS OF ROLLING STOCK

To maintain high degree of cleanliness, following schedules (Table 7.2) are proposed

for cleaning of rakes.

Table 7.3: Schedule of Cleaning

S.

No

.

Kind of Inspection Maint.

Cycle

Time Maintenance Place

1. Outside Cleaning (wet washing

on automatic washing plant)

3 Days 10 mins Automatic washing

plant of Depot Single

Pass

2. Outside heavy Cleaning (wet

washing on automatic washing

30

days

3 Hrs Automatic washing

Plant & heavy cleaning



plant and Front Face, Vestibule/

Buffer area, Floor, walls inside/

outside and roof Manually)

on nominated stabling

line

7.6 DEPOT CUM WORKSHOP

The layout plans of proposed Main Depot cum Workshop will be evolved for

maintenance & POH of 93 Rakes of 12 car length. The concept plan will include

following operational features.

7.7 OPERATION FEATURES

The rake induction and withdrawal from depot to the open line will have to be so

planned that the headway of open line is not affected. For the purpose, facilities for

simultaneous receipt and dispatch of trains from depot to open line should be

created. The stabling area should be interlocked with the open line so that the

induction of train from the stabling can be done without loss of time. The rake

washing can be done at automatic coach washing plant provided at the entry of

depot i.e before rake is placed on stabling lines.

The other movements in the depot, viz from the stabling to the inspection shed or

workshop and vice versa may be non-interlocked. An ART line and 2 emergency re-

railing lines will be provided from which emergency rescue vehicles can be

dispatched to open line in the event of any emergency. To cater to the peak

requirements, all trains except trains under maintenance would be in the service.

However during the off-peak hour in daytime, approximately half of the trains will be

withdrawn from the service. There would be pathways between the stabling lines,

which are necessary for the “Safe to Run” examination and to facilitate the workers

to move trolleys for the sweeping work. The scheduled inspections are envisaged to

carry out during the day off-peak hours and night.

The stabling and the yard layout would be at grade level for least power

requirements in shunting movements and to avoid accidental rolling of Rolling Stock

resulting into accidents and damages to the property.

7.8 INFRASTRUCTURE FACILITIES PLANNED AT DEPOT

The schedule sequence for rakes with 10 days frequencies of inspection will be as

given below:



As per the above frequency of inspections, the visits of rakes to car sheds are as

given in Table 7.4 below:

Table 7.4: Rake Visit periodicity for Depot

Rake visits to car shed/depot

Schedule Total visits in 18 months Average visits per year

TI 43* 28.667

IA 9 6

IC 2 1.333

POH 1 0.667

*includes one additional inspection in car shed after POH in workshop

Assumptions: To assess the number of lines required to maintain the rakes,

following assumptions are made:

For Washing of rakes, an automatic washing plant will be proposed. Hence no

separate washing line is needed exclusively for washing. However, one line will be

provided for heavy cleaning (Manual cleaning of Floor, walls inside/outside and

roof).

In a day, two rakes are taken for Trip Inspection on a pit line.

In a day, one rake is taken for IA schedule on a pit line.

Pit line occupancy for IC schedule (Down time 16 hrs) is taken for two days.

Based on the number of holidays as given below, total number of working days is

taken as 300 for calculating the requirement of lines.

No. of days of Public holidays in a year : 13

No. of Sundays in a year : 52

No. of available working days in a yea : 365 - 65 = 300 days



Table 7.5: Total requirement of Maintenance Lines in Depot

Schedule

Schedule

per rake

per Year

Total Arising per

day for designed

holding of 78 of 12

car

Rakes

attended

on a line /

day

Number

of lines

needed

Lines

required

(roundoff)

Trip Insp. 28.67 7.45 2 3.73 3

IA 6 1.56 1 1.56 1

IC 1.33 0.35 0.5 0.69 1

Add for unscheduled shed attention & adjustment/shunting etc. 1

Total no of lines needed in Inspection shed 6

Similarly lines needed for Workshop Activities

Schedule

Schedule

per rake

per Year

Total Arising per

year for designed

holding of 78 of 12

car

Time taken

in over

haul

Number

of lines

needed

Lines

required

(roundoff)

POH 0.667 52.03 24 2.17 2

Add for unscheduled major Repairs /Lifting & adjustment/shunting

etc. 2

Total no of lines needed in Workshop 4

Total Lines needed in Depot for Maintenance 10

All lines in workshop to be provided with lifting facility

7.9 LINES FOR STABLING OF RAKES

There will be a holding of 48 rakes of 12-Car in year 2041, and elaborate

arrangement for stabling of these rakes will have to be done in depot cum work

shop, terminal stations and at few places enroute the section.

The train operation plan envisages operation with 12-Car composition in the

inception year itself in year 2021. Accordingly, all the infra structure facilities has

been provided for 12-Car length and stabling lines are also provided for 12 car length

and accommodate trains as detailed in Table 7.6below:

Table 7.6: Stabling Line Provisions of 12-car length

Year 2021 2031 2041

Stabling lines at the terminal station for

morning & evening peak period services 4 4 4

En-route Stabling lines at convenient

location such as Bhivandi Road or/and

Taloje or/and Kalamboli

------ 9 20

Rakes to be stabled in the Depot 15 20 24



Total Stabling Lines of 12 car length 19 33 48

Twenty five (24) number of 12-car length-stabling lines, Five (5) number of

inspection lines and Five (5) number of workshop lines will have to be provided in

the main depot. For starting the morning services, it will be necessary to stable the

rakes at the terminal station & suitable sidings enroute as indicated above.

Design of Stabling Lines

The length of 12 cars Rolling Stock is approx 252 m Stabling lines are designed for

278 m length or more to cater for provision of the friction buffer stops and the

signaling/interlocking needs - assuming the speed of the Rolling Stock in the depot to

be 15 kmph. The breakup is as follows:

252 m (length of 12 car Rolling Stock) + 15 m (length of the Buffer for 12 car Rolling

Stock & signaling / interlocking needs) + 1m (clear distance between Rolling Stock &

buffer) + 10 m (clearance between three 4 car trains running initially) = 278 m.

Accordingly, stabling lines as well as inspection & workshop lines be designed for 280

m length. The track centre in stabling lines would be 4.9~5.3m and in inspection lines

6.25~8.5m. Thus, sufficient space shall be provided to construct pathway in stabling

area and in inspection shed to provide easy access for internal train cleaning /

attention to equipments in passenger area.

7.10 POWER SUPPLIES

An auxiliary substation of 2X3000 KVA capacities has been planned for catering to

the power supply requirement of the main depot. Details of connected load, feeder

may be worked out during detailed designing stage.

7.11 STANDBY POWER SUPPLY

The standby power supply will be proposed through silent DG set of 3X320 KVA

capacities to supply all essential loads without over loading.

7.12 WATER SUPPLY, SEWERAGE AND DRAINAGE WORKS

In-house facilities should be developed for water supply for the entire depot cum

workshop. Sewerage, storm water drainage may be given due care while designing

the depot for efficient system functioning. Rainwater harvesting should be given due

emphasis to charge the underground reserves.

7.13 ENGINEERING TRAIN UNIT WORKSHOP

Since the workshop cum depot is designed optimally, it would not be wise to waste

its capacity in maintaining the other than passenger Rolling Stock vehicles. Carrying

these vehicles to the inspection shed affects the RS maintenance as shunting is also

involved. Therefore other vehicles like diesel locomotive, tower wagons, wagon for



material trains etc may be housed and given required inspection attention in a

separate shed called ETU workshop, for which 2 lines shall be provided in the main

depot. However for the heavy lifting needs, these vehicles may be taken to the area

where such facilities are available.

7.14 PLANT AND MACHINERY

Requirement of major plants and machinery, which are vital for operational needs, is

given in Annexure-I.

7.15 DEPOT LOCATIONS

The proposed Corridor would require a dedicated Depot cum Workshop (Main

Depot) in the inception year 2021 itself. A plot of 34.8 hactare has been marked at

Kalwar between Kalwar and Dunge station.

Car Depot Site requirements

The pre requisites of coach maintenance depot site are as under –

i. A plot size of adequate area - about 34 Ha for main depot

ii. Proximity to alignment: Site must be located as close to the alignment as

possible so that no time is wasted in placement/retrieval of rakes from depot.

In addition, it will save expenditure in constructing link from corridor to

depot,

iii. Ease of movement – there should not be any obstruction to movement of

rakes in either direction so that defective rakes can be withdrawn from

service & placed in depot for maintenance and healthy rakes can be retrieved

from depot & pressed in service.

iv. A store depot within car-depot premises is to be set up.

The conceptual layout plan of Depot with above infrastructure will be developed

upon finalization of suitable location with adequate area for the depot.

Depending upon the type of rolling stock procured and recommendations of original

equipment manufacturers of rolling stock and sub assemblies, exhaustive list of

machinery and plants along with tool and tackles shall be prepared for procurement

so as to develop healthy maintenance practices for reliable operation of the rolling

stock. An indicative list of such items is given in annexure I.

For maintenance of OHE, PSI, signaling, Telecom, P-WAY, Works etc standard

facilities as per practice in vogue shall be planned at the time of detailed project

report. Special attention shall be however given for procurement of machinery and

plants to introduce mechanized maintenance to reduce dependence on man power.



ANNEXURE-I

LIST OF MAJOR PLANT & MACHINERY FOR DEPOT

Sl no. PLANT & MACHINERY Qty.

A. Material Handling

1 Travelling over head EOT cranes for workshop 35/10T 2

2 Travelling over head EOT cranes for inspection bay 2.0T 2

3 Travelling over head EOT cranes for ETU shed 5T 1

4 Jib crane for workshop 3 T 2

5 Synchronized pit jacks system for lifting (3 cars as one set) 1

6 Car body stands for keeping car shells 32

7 Dummy bogies 6

8 Mobile lifting jacks-15T 2

9 Mobile lifting jacks 10T 2

10 Battery powered Electric locomotive 2

11 OHE Inspection car 2

12 Road mobile Crane 5T cap 1

13 Fork lift trucks 3T cap 2

14 Pallet trucks 4

15 Pick up van 1

16 TATA Truck 2

B. Wheel shop

17 500T Hydraulic wheel press 1

18 Vertical boring m/c / Turret Lathe for wheel machining 1

19 Multipurpose Wheel Lathe/CNC surface wheel lathe 1

20 CNC Axle turning lathe/Axle journal turning & burnishing lathe 1

21 Axle UST inspection machine 2

22 Induction Heater 2

23 Bearing Extractor 4

C. Bogie shop

24 Bosch Tank : Bogie wash/cleaning plant (manual) 1

25 Bogie static load testing m/c 1

26 Shock absorber testing m/c 1

27 Spring scragging &testing m/c 1




28 Magnacheck crack detector 1

29 Glowcheck crack detector 1

D. Rotating m/cs

30 Air blow plant/Cleaning booth for Traction Motor 1

31 Baking Oven for traction motor drying 1

32 Dynamic balancing 1

E. Other m/cs

33 Under floor Pit wheel lathe, Chip crusher and conveyor, Electric

tractor for movement over under floor wheel lathe 1

34 Bogie Drop Table 1

35 Automatic Washing plant for Metro cars. 1

36 High-pressure washing pump for front and rear end cleaning of

cars 2

37 Turn table for one car 1

38 Turntable for bogies 6

39 Driving Cab Simulator 1

40 Water de-mineralizing plant (Distillation plant) 2

41 Painting booth for separate parts 1

42 Floor cleaning machine 5

43 Welding equipments (Mobile welding, oxyaccetelene, fixed arc

welding) 5

44 Compressor 500Cfm, 10 kg/sq.cm for depot air supply 2

45 DG set 320 KVA 3

46 EMU Battery charger 2

F. Machine shop

47 Guillotine Shearing m/c 1

48 Shearing, punching & cropping 1

49 Universal tool cutter & grinder 1

50 Vertical surface grinder 1

51 Centre lathe 2m bed 1

52 Centre lathe 1m bed 1

53 Radial drill m/c 1

G. Test Benches/Instruments

54 Traction motor test console 1




55 Motor compressor test bench 1

56 Brake test bench 2

57 Speedometer test bench 2

58 Door test bench 2

59 Inverter test bench 1

60 Other test benches (MCB, RMPU etc.) 1

H. Furniture/material storage/Small tools

61 Vertical carousel storage system for DCOS store 1

62 Computer MMIS with LAN connectivity for depot 1

63 Storage racks LS

64 Industrial furniture, work benches etc. LS

65 Electric and pneumatic tools LS

66 Measuring and testing equipments LS

67 Tool kits LS

68 Other small tools, machines & misc items etc LS

7. maintenance depot and workshop - mumbai railway … chapter 7... · 7. maintenance depot and...

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